"VCC-120003 EN 2009-04-11"

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Gearbox fluid, replacing

Warning! Avoid skin contact with the gearbox
fluid.
Note! Use only gearbox oil, Volvo P/N 116 1540-8
(1 litre container), 116 1640-6 (4 litre container).
Conditions
The oil should be replaced only in the two
following instances:
Where diagnostic trouble codes (DTCs) TCM
0042 and TCM 0046 are stored, in which case
the diagnostic function activates the warning
lamp in the following circumstances.
The gearbox control module (TCM) receives
data about the operating temperature of the
gearbox fluid while the car is being driven. TCM
0042 is stored after an accumulated amount of
time.
Diagnostic trouble code (DTC) TCM 0046 is
stored if the gearbox fluid temperature exceeds
150 C for more than two minutes.
In cars used in continuous taxi service or used
for towing a trailer or caravan for most of its
mileage, the oil must be replaced at a service
interval of 75, 000 km 5000 km. This is to
conform to the regular service program.
Warning! The oil may be very hot if the car has
just been driven. Avoid skin contact.
Draining
Remove:
- the splash guard under the engine
- the oil plug. Drain the gearbox oil.

Installing the oil plug

Use a new gasket.
Tighten the plug. Tighten to 40 Nm.

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Install the protective cover.

Draining oil
Remove the return hose on the control system
cover.
Install a plastic plug in the connection on the
cover.
Detach the return hose in the cooler. Align the
hose upwards and reconnect it to the cooler.
Install a transparent plastic hose on the oil
return hose connection.
Place a container beneath the hose to catch the
oil.

Refilling
Apply the handbrake. Move the gear selector
lever to position P.
Fill with approximately 2 litres of oil.
Start the engine. Allow the engine to idle.
Turn the engine off when air bubbles start to
become visible in the hose.
Fill with approximately 2 litres of oil.
Start the engine again and let it idle.
Turn the engine off when air bubbles start to
become visible in the hose.
Remove the hose from the oil cooler hose.
Detach it from the connection to the cooler.
Install the hose in the normal position on the
cooler and the gearbox.
Further filling
Fill with approximately 2 litres of oil.
Apply the handbrake.
Start the engine. Allow the engine to idle. Move
the gear selector through all the gear positions.
Wait 45 seconds in each gear.
Checking the oil level
See Oil level, checking .
The capacity of the gearbox is 7.1 0.25 litres.
(MAX, MIN).
Note! After replacing the gearbox oil, the
Gearbox oil change counter must be reset. See

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Resetting Gearbox fluid change counter .

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